Offered through SAE International

I.D.# C0718, Duration: 2 Days

While most passenger car brake systems are quite robust and reliable under typical operating conditions, high-performance driving and/or racetrack operation generally require alternative design solutions to optimize consistency and longevity. Whether it is brake fluid fade, cracked rotor discs, chronic knockback, or insufficient brake pad life, the stresses of motorsports can pose unique challenges to even the very best brake system designs. Consequently, ceramic rotors, six-piston calipers, adjustable balance bars, and titanium backing plates have all made their way onto the high-performance brake system scene, but what is the right answer for your application?

This seminar has been designed to assist you in answering that very question. The day begins with a concise yet thorough analysis of brake system design factors relevant to all types and categories of high-performance vehicles. The principles of energy conversion, gain, balance, and deceleration are discussed and supported with straightforward mathematical models, allowing attendees to realize the compromises that must be considered when designing from a system perspective.

From selecting an appropriate brake pedal ratio through the calculation of caliper effective piston area, the second portion of the seminar dives into the details of brake system component design. Based upon the principles learned earlier in the day, attendees will quickly realize that just as with proper system design, brake system component design is an exercise in managing engineering trade-offs. As a result, the material presented will not disclose what components to choose as much as how to choose them.

Day two of the seminar concludes with a design exercise that will allow attendees to put into practice several of the key concepts learned throughout the seminar. Detailed course notes and illustrations are provided along with a copy of High-Performance Brake Systems: Design, Selection, and Installation for on-the-job reference.

Learning ObjectivesBy attending this seminar, you will be able to:

Estimate brake system energy capacity

Approximate brake system gain requirements

Calculate vehicle deceleration

Establish brake proportioning for ideal balance

Determine pedal ratios, booster output, and hydraulic system gain

Discuss the differences between brake fluid chemistries

Specify brake caliper components

Differentiate between brake pad friction materials

Select rotor technologies for application-specific needs

Who Should AttendThis course has been developed for individuals involved in the specification, design, installation, maintenance, and performance of brake systems and their associated components in high-performance and/or racing applications; however, the fundamental principles and design considerations presented apply to all facets of brake system engineering.

In addition to individuals involved directly in brake system design, this course can be valuable to those responsible for chassis design, suspension tuning, tire optimization, and overall vehicle dynamics in high-performance applications.

PrerequisitesAn undergraduate engineering degree or a strong automotive technical background is highly recommended. A basic knowledge of college algebra, college physics, and a familiarity with vehicle hydraulic brake system functionality is required to participate in the final seminar design exercise.

Seminar Content

Day OneModule 1: Energy Conversion

The Conservation of Energy

Types of Energy

Energy Transformation

Calculating Brake System Temperatures

Module 2: Tires

Brake Forces & Tire Slip

The Mu-Slip Curve

Calculating Maximum Deceleration

Module 3: Gain

Gain & Force Distribution

Brake Component Gain

Brake System Gain

Calculating Stopping Distance

Compliance

Module 4: Brake Balance

Brake Force and Corner Weight

Static and Dynamic Weight Distribution

Ideal Brake Balance

Why Ideal Brake Balance Matters

Module 5: Apply System

Brake Pedal Design & Function

Brake Booster Design & Function

Master Cylinder Design & Function

Balance Bar Design & Function

Proportioning Valve Design & Function

Module 6: Brake Fluid & Hoses

Boiling Points and Water Adsorption

DOT Ratings

Hydraulic Circuit Design

Brake Hose Design & Function

Day TwoModule 7: Calipers

Caliper Design & Function

Taper Wear and Piston Count

Caliper Mounting

Caliper Body Design

Knockback

Module 8: Brake Pads

Brake Pad Design & Function

Brake Pad Fade

Friction Material Categories & Chemistries

Friction Mechanisms

Module 9: Rotors

Rotor Design & Function

Rotor Cooling

Solid & Vented Rotors

One-Piece & Two-Piece Rotors

Cross-Drilled Rotors & Slotted Rotors

Module 10: Design Exercise

Brake Force Analysis

Deceleration Analysis

Weight Transfer Analysis

Brake Balance Analysis

Instructor(s): James Walker, Jr. James Walker, Jr. is currently a Principal Engineer specializing in chassis, brake, and electronic brake control systems at Carr Engineering, Inc. His prior professional experience includes brake control system development, design, release, and application engineering at Kelsey-Hayes, Saturn Corporation, General Motors, Bosch, Ford Motor Company, and Delphi.

Mr. Walker created scR motorsports consulting in 1997, and subsequently competed in seven years of SCCA Club Racing in the Showroom Stock and Improved Touring categories. Through scR motorsports, he has been actively serving as an industry advisor to Kettering University in the fields of brake system design and brake control systems. Since 2001, he has served as a brake control system consultant for StopTech, a manufacturer of high-performance racing brake systems.

In addition to providing freelance material to multiple automotive publications focusing on chassis and brake technology, Mr. Walker is the author of High-Performance Brake Systems: Design, Selection, and Installation. In 2005, he was presented with the SAE International Forest R. McFarland Award for distinction in professional development and education. He obtained his B.S.M.E. in 1994 from GMI Engineering & Management Institute.